Dual-dimensional optimization of coil configuration and excitation voltage for enhanced dynamic response in high-speed on/off valves

High-Speed on/off Valves (HSVs) are the primary flow-control elements in aerospace digital hydraulic systems, where minimizing switching delay is essential for achieving superior dynamic response and control accuracy. This study proposes a dual-dimensional optimization framework that synergistically combines coil structure design and excitation voltage modulation. A parallel dual-coil configuration is adopted to replace the conventional single-coil architecture, substantially increasing the current change rate of the electro-mechanical converter. Building on this hardware improvement, an improved multi-stage voltage control strategy is developed to attenuate current variation amplitude during switching transitions. Furthermore, adaptive threshold functions are established based on the supply pressure and the duty ratio of control signal. Through the synergistic integration of innovative coil physical layout and intelligent voltage regulation, the dynamic performance of the HSVs is significantly improved, demonstrating a reduction in opening time by 74.5%, closing time by 84.1%, an increase in controllable switching frequency to over 100 Hz, and a decrease in coil temperature rise by 50.1%. Both simulation and experimental results validate the effectiveness of the dual-dimensional optimization approach, providing new technical insights for enhancing the dynamic performance of HSVs in aerospace and other high-demand applications.